Catalytic reduction of carbonyl compounds



Patented Dec. 1, 1931 UNITED STATES" PATEN'F OFFICE muons o. JAEGEB, or GRAFTON, rmmsravmm, ASSIGNOR 'ro 'rnn snnnan commemorrmsnpnerr; rmmsrnvmra, a conroaa'rron or DELAWARE CATALYTIC REDUCTION OF cannom COIPOUNDS Io Drawing. v

This invention-relates to. catalytic reductions of carbonyl com unds such as oxides -of carbon, ketones,'al eh des, acids, esters,

alcohols, others, etc., imw ich the reduction takes place at least partially in the earbonyl According to the present invention carbonyl compounds are reduced by means of hydrogen or gas containing hydrogen in the presence: of a new class of contact-masses.

The contact masses used in the present invention contain base exchange bodies or their. derivatives. Under the term .base exchange bod are included all natural or artificial bodies which possess the properties of exchan their bases for'other bases of salt I solutions. The base exchanging products the catalytic value of the base exchanging power or in many cases may used in making catalytic compositions of the present invention or as initial material for derivat ves to be so used may possess high amphoteric metal oxides. Two-component zeolities are the reaction products of two types of initial components, that is to say,

metallates and silicates, (using the term metallate in a somewhat broader sense as will be defined further on the description), or

metal salts and silicates. Frequently more than one member of a type may enter into reaction, that is to say, a silicate may react with V more than one metallate or more than one metal salt. Themulti-com orient zeolites are the reaction products 0 a at least three types of components, that isto say, at least one silicate, at least one metallate, and at least one metalsalt.

The base exchange bodies, both zeolites and non-silicious base exchange bodies, may be associated with diluents preferably in the Application fled February 21, ma- Serial at. 258,065.

form of a-(physicall homogeneous structure, as will be escribed below. Either diluted or undiluted base exchange bodies may be present in the contact masses used in the present invention, or their derivatives maybe resent, but it should be. understood that w ereever base exchange bodies are referred to both diluted and undiluted products are included.

' Base exchange bodies, both zeolites and nonsilicious base exchange bodies, may also be transformed into derivatives which possess many of the chemical and most of the physical characteristics of the parent base exchangebodies'. Such derivatives may be salt-like bodies, that is to say,'the reaction products of base exchange bodies with comounds containing anions ca ableof reactmg with the base exchange 7 odies to form products which possess many of the pr rtles' of salts, A further class of derivatives are the acid leached base exchange bodies.

When a base exchange body is subjected to leaching by acids, particularly dilute mineral acids, the exchangeable bases are first graduall removed. The resulting roducts contain oth the-more basic and t e more acidic components of the non-exchangeable nucleus of the base exchange body with or without a portion of the exchangeable bases.

As-the leachin is carried on further, more and more of t e relatively positive components of the non-exchangeable'nucleus are removed, and if carried -.to completion the leached product contains only the relatively acid components of the non-exchangeable nucleus. In the case of zeolites the final product from long continued leaching is a. complex silicic acid which has many of the physical properties of the original base exchange body. The non-silicious base exchan e bodies and the two-component and multi-component zeolites, and the salt-like bodies and leached derivatives obtained from these will be collectively referred to in the present specification as permutogenetm odies, and it is understood that this term will haveno other meaning.

Catalyticall associated wit diluted or undilutedpermutogenetic bodies in 'four main forms, as 'folactive-components may be v where the diluents by reason of lows :--(1) They may be-physically admixed with or impregnated into the permutogenetic products. (2) They may be physically homogeneously incorporated into the permutogenetic products before the latter have been completely formed in the form of catalytically active diluent bodies or in the form of diluents which have been impregnated with catalytically active substances. (3)

They may be chemically combined with or in the permutogenetic products in nonexchangeable form, that is to say, they may form a part of the non-exchangeable nucleus of the base exchange body present .in the final contact mass or which is transformed into the derivatives, or they may be chemically combined with the base exchange 1 bodies in the form of catalytically active anions which form with the base exchan e body salt-like bodies. (4) They may e chemically combined in exchangeable form either during the formation of the base exchange body or by base exchange after formation. Obviously of course the same or different catalytically active components may be present in more than one of the above described forms, and it is an advantage of the present inventionthat catalytically active substances may be introduced in a wide variety of forms which gives a large field of of some of the contact masses of the present invention.

While three of the methods of combinatlon of the catalytically active substances may be effected with undiluted as well as diluted permutogenetic products, it has been found that for most reactions homogeneously diluted permutogenetic contact masses are of advantage, particularly where the diluents are of a physical nature such as to exert adesired influence on a catalytic activty of the contact masses, as when, for example, diluents are rich in silica, which has been fouhd to havb an activatingx power, or

igh porosity, capillarity, or surface energy may be considered as physical catalysts or-activators.

Base exchange bodies used in contact masses of the resent invention behave as if rated chemically, appears to be without force,

which makes it reasonable to assume that the molecular weight is so high as to completely mask the effect of the law. It is of course possible that the base exchange bodies, or

some of them, may be solid solutions of a plurality of related compounds of lower molecular weight. It has not been possible hitherto to definitely settle this question, as

base exchange bodies are not readily capable of structural chemical analysis. The present invention is of course not limited to any theory, but irrespective of the underlying rea sons the fact that catalytically active components may be chemicall introduced in any desired proportions is of enormous importance to the catalytic chemist and gives him the power to produce an almost unlimited number of finely and gradually toned catalysts or contact masses for the reductions of carbonyl compounds and in all cases the contact masses produced are highly effective by reason of the desirable physical structure of the permutogenetic products contained therein and the wide limits of homogeneous dilution of catalytically active molecules or atoms with resulting uniformity and smoothness of action, which is of great importance, particularly in the sensitive reactions such as certain reductions of oxidesof carbon for which contact masses used in the present invention are. peculiarly adapted.

.In addition to the important characteristics with which permutogenetic products endow' the contact masses of the present invention it has been found that for many of the reactions coming within the scope of-the present invention it is desirable to stabilize. the contact masses, and this may be effected by associating with the permutogenetic products or incorporatin or forming therein compounds of the a a'li forming metals, that is to sa ,the alkali metals, the alkaline earth meta and the strongly basic earth metals.

These compounds appear to slow up or smooth out the catalytic reaction, and will be referred to throughout this specification as stabilizers. The stabilizers may be non-alkaline, weakly alkaline or strongly alkaline, depending on the reduction products and on the nature of the catalytically active components used. It is a great advantage of the present inventionthatinthe normal formation of base exchange bodies alkali forming metal oxides are present as exchangeable bases, and

. whether used without acid treatment or treatg 65 they'were pr ucts of extremely high moleced with acid, they form stabilizers which are combined in or associatedwith the resulting permutogenetic products in an-extremely fine state of division in which the stabilizers are peculiarly active. Thus base exchange bodies containing alkali forming metal exchangeable bases may be considered as complex stabilizers.

In addition to the use of stabilizers which are important in a large number of reductions and hydrogenations included in the.

'scope of the present invention, it has been as dehydrogenation catalysts may be added.

to enhance and tone the catalytic activity of the catalysts or the operation of the stabilizers. Similarly in some cases oxidation catalysts, such as those containing metal ele -ments of the fifth and sixth groups of the periodic system may greatly improve the effectiveness of the contact mass used, especially where it is desirable to produce intermediate products which in some cases are relatively unstable. Some other reduction and sharingthe advantages flowing from its desirable physical structure and chemical properties. Of course both stabilizer and stabilizer promoters may be mixed partly or wholly with permiitogenetic products and a single stabilizer or single stabilizer romoter may be present partly in physical a mixture and partly in chemical combination, as will be clearto the skilled base exchange chemist.

The base exchange bodies which form the important components or initial material for derivatives in contact masses of {the present invention may be prepared in anyof thewell known methods. Thus for example, twocomponent zeolites may be prepared by wet methods, in which the metallate components or metal salt components, part or all of which may be catalytically active, are caused to react with soluble silicates to form zeolites of alumino silicate or aluminum'double' silicate types, or the components may be fused,

salts of metal acids, such as the oxyacids of reactions involve the splitting off ofwater,

and may also involve molecular condensations. In such reactions it is very desirable to incorporate catalysts or catalytic'components which are not specific reduction catalysts but which may favor dehydration,

splitting off of carbon dioxide or condensa-' tion. Such catalysts or catalytic components which are not specific catalysts for the reaction in which-they are being used under the reaction conditions obtaining will be. ree

ferred to throughout the specification as stabilizer promoters, as theyappear to en- ,hance the toning effect which can-be achieved .by stabilizers, The use of this expression should, however, in no sense be taken to limit the invention to a particular theory ofactionof these non-specific catalysts and in fact in some cases stabilizer promoters may be present where there are no stabilizers.

The'tremcndous range of chemical groups which may be combinedi'n or with or incorporated in permuto netic productspermits a wide choice of sta ilizer promoters as well i as specific catalysts and permits their association with the contact masses in an excient' form. Thus many base exchange bodies or their derivatives may be considered "lizer promoters, as all of these elements may "tremely homogeneous'and catalytically efli be piesentin the same chemical compound metals at the fifth and sixth groups, which in at least one stage of oxidation are not strictly speaking amphot-eric, but which products are capable of reacting with silicates to form zeolites, or with other components to form non-silicious base exchange bodies...

for many purposes zeolites formed under con-.

ditions resulting in a final reaction which is acid to phenolpht-halein but alkaline to litmus are of advantage. It is not definitely .known whether products produced undersuch circumstances are homogeneous chemical compounds, although in many ways they behave as such. There is, however, reason to believe.

that in some cases at least mixtures of base exchanging and non-base exchangingpolysilicates may be produced. 7 For the purpose of the present specification a product will be considered as a base exchange product if it has any base exchange power at all.

It is desirable for many purposes and particularly where two-component zeolites of high base exchanging power are needed to add the relatively acid components, *for example, metal'salts inythe case ofaluminum double silicate type ofsilicates, to the relatively more alkaline components such as for example soluble silicates. By these means a continuous alkalinity is insured, and this method may be considered as the preferred method in most cases, but the opposite procedure is advantageous for certain contact masses and, is included in the invention.

Multi-component zeolites may be prepared by any of the foregoing methods using at least-three types of components, that is to say, at leastone metallate, at least one metal salt and at least one soluble silicate. In the ease of multi-component zeolites, as in the case of two-component zeolites, the conditions of alkalinity should be observed, and for many resemble the aluminum double silicate type of two-component zeolites, and finally if the metallates and metal salts predominate over the silicates the resulting producthresembl'es more or less non-silicious base exchange bodies. It will be clear that there is no sharp defining line between the three types of mult icomponent zeolites, and one shades into the other as the proportions of the different components vary. It is an advantage of the multi-component zeolites over the two-com ponent zeolites that the choice of catalytically active components iswider, as some catalytically active elements or groups can only be incorporated in the form of metallates and others only in'the form of metal salts. In a 'multi-component zeolite each catalytically active group can be incorporated in the form in which it is best available.

Non-silicious base exchange bodies are'produced by the general methods described above, but instead of bringing about reactions between silicates and other metal oxide components, two or more oxymetal compounds are caused to react, in general, at least one will be a metallate and at least one a metal salt, or in some cases it is possible to bring about action between two different metallates in which one negative radical is more acidic than the other. It is possible to produce nonsilicious base exchange bodies in which a plurality of metal oxides are present. It is also possible to produce non-silicious base exchange bodies in which a single metal is present. Thus forlexample, some metals may be sufiiciently amphoteric in character to form both metallates and metal salts which are capable of reactin with each other to produce base exchange bodies.

A special method of producing non-silicious base exchange bodies consists in the gradual neutralization of strongly alkaline salts of the oxyacids of metal elements of thefifth and sixth groups in stages of oxidation in which they are sufliciently amphoteric. The neutralization of other strongly alkaline metallates may also bring about formation of non-silicious base exchange bodies. The converse method, whereby non-alkaline salts of suitable metals are gradually treated with alkali until the reaction is sufficiently. alkaline to permit the formation of'base exchange bodies, may also be used.

Many metals are capable of entering into the base exchange formation only in certain stages of oxidation, and it is sometimes necessary to introduce such metals in a stage of oxidation different from that desired in the final base exchange body, the change of stage of oxidation being preferablyefl'ected during the formation of: the base exchange body. Certain other elements may be incorporated in the form of complex compounds of the most various types, such as for example, ammonia complexes and the like.

In addition to the artificial base exchange bodies briefly described above, natural base exchange bodies, such as nepheline, leucite, fclsnar, and the like, may be used.

The most important contact masses for many reactions contain ermutogenetic products, in which preferably the diluents are homogeneously incorporated into the base exchange bodies before formation of the latter, or at least before the base exchange body has set after formation. Many diluents, both inert, stabilizing, activating, catalytically active, or having stabilizer promoter efl'ects,

can be used. A few of "the diluents will be briefly enumerated :kieselguhrs of all kin ds, particularly natural or treated Celite earth, silicious powders of various types, powdered permutogenetic products, natural or artificial powders of rocks, stones, tuffs, trass, lava, and similarly volcanic products which are frequently highl porous, greensand, glauconite-orits aci 'leachedderiva tive glaucosil, pulverized slag wool, cements, sand, silica gel, pulverized earthenware, fullers earth, talc, glass powder, pumice meal,

asbestos, graphite, activated carbon, quartz -meal, various pulverized minerals rich. in

quartz, metal powders and metal alloy powders, salts of oxymetal acids such as tungstates, vanadates, ehromates, uranates, manganates, ,cerates, molybdates, etc., particularly copper salts of the above, silicates, such as copper silicate, iron silicate, nickel silicate, cobalt silicate, aluminum silicate, titanium silicate, minerals or ores, especially those rich in copper, etc. Finely divided diluents are of great advantage, especially when the average 50, act with certain of the-base exchangebodies particle size is less than 60 microns, in which case the diluents possess high surface energy, which increases the adsorptive and absorptlve capacity of the contact mass, the diifusion spe'edandporosity. These finely divided' diluents may be considered as physical catalysts or activators. Diluted permutogenetic bodies may also befinely divided and used as part or all of the diluents of other base exchange bodies.

The following nine methods are the most effective for the introduction of diluents, but

J amples anyother suitable methods can be used. Ex-

aredescribed in detail in the .copending lei :plicationof J aeger and Bertsch, Serial 0.

' 95,771, filed March 18, 1926, and any of the methods described can "be used-in incorporating diluents in the present invention:

(1) The diluents may be mixed with one or more liquid components of the base exchange bodies to be formed when the latter are prepared by wet methods. (2) Components, either catalytically acthe, stabilizer promoters, or others, may be precipitated or impregnated into diluent bodies which are then incorporated into the base exchange bodies by anysuitable methods of incorporation.

(3) Diluents may be mixedwith base exchange bodies when the latter are still in the form of gels, by knead ing br stirring, in

- which case the base exchange gel behaves as an adhesive. The homogeneity and uniformity of the distribution of the diluents is of course not quite so great by this method as by method (1), butfor the catalytic reductions and hydrogenations of carbonyl com} ounds extreme uniformity is not essential. (4) Diluents may. be formed during the formation of base exchange bodies by mixing suitable compounds with the components of the base exchange bodies so that the diluent particles are precipitated during formation.

' Protective colloids may be added to prevent coagulation of the diluent particles before ides.

the base exchange bodies have become sufiiciently set. (5) Compounds may be added which reforming components to produce diluents, for instance salts of the metal acids of the fifth and sixth groups may be added in sufiicient excess so that they react with components-of the. base exchange body to form insoluble diluents, as for exam'plewith heavy metal ox- (6) Preformed base exchange bodies, di luted or undiluted,artificial.or natural, can be impregnated with true or colloidal solutions of catalytically eifective components and-then dried.

(7) A preformed base exchange body, diluted or undiluted, may be impregnated with ofidethods for incorporating diluents I a plurality of solutions which react v to reci itate an desired diluents.

ad ed to the components forming a base exchange body,'wh1ch after formation retains the com ounds insolution and is dried with-.

out was ing or is treated to precipitate the compounds.

(9) Naturalbase exchange bodies, or arfi fficial base exchange bodies, diluted or undiluted, or their derivatives, may be impregnated with solutions of the desired com- 8) luble dlluentv compounds may be i pounds, which are then precipitated by means of reactive gases.

The nucleus or non-exchangeable portionof the molecules of the base exchange bodies is ordinaril considered to consist of two Hpes ofoxi es, namely, relatively basic-met; oxides, usually amphoten'c, and relatively acidic oxides, such as SiO,, some amphoteric metal oxides and some metal oxides which mmum,some rare earths,titanium,zircomum,

tin, lead,'thorium, niobium, antimony, tantalum, chromium, molybdenum, tungsten, uranium, vanadian, manganese, iron, nickel, cobalt, platinum, palladium. Compounds of these elements may be introduced singly or in mixtures in any desired proportions, and may be in the forin of simple or complex ions.

It should be understood that some of the ele- 'ments 'in certain stages of oxidation may be b e s introduced either as metallates or metal salts.

Others may be'introduced in only one form, and'still-others may be introduced in a s of oxidation other than that desiredin e final base exchange body or in the form of complex compounds. Among the complex ionogens are ammonia, hydrocyanic acld, ox-

alic acid, formic acid, tartaric acid, citric acid, g'lycerine, and the like. v Many of the. metals are specific catalysts,

'others are stabilizers, and still others are stabilizer promoters. Naturally the status of an element as catalyst or stabilizefosro- "mol'er will vary with the particular uction '01- hydrogenation reaction for which" I thefinalcontactmassistobeused,audthie choice of catalysts andstabilizerjpromoters I together with the proportions will be deter mined by the particular catalytic redu'ction .or hydro nation of the particular carbonyl compoun Examples of components forming the 1'81? for whichthe contact mass is toatively acid ortion of the base exchange nucleus are a kali metal silicates, which are soluble in alkali, and alkali metal salts of acids, such as those of boron, phosphorus, nitrogen, tin, titanium, vanadium, tungsten,

. chromium, niobium, tantalum, uranium, an-

timony, manganese, etc.

The exchangeable b. scs of the base exchange bodies may be s bstitutcd by base exchange, and the elements which can be intro duced singly or in admixture by base exchange are the following z-copper, silver, gold, ammonium, beryllium, calcium, manganese, caesium, potassium, sodium, zinc, strontium, cadmium, barium, lead, aluminum, scandium, titanium, zirconium, tin, antimony, thorium, vanadium, lithium, rubidium, thallium, bismuth, chromium, uranium, manganese, iron, cobalt, nickel, ruthenium, palladium, platinum and cerium.

Depending on the reactions in which the contact mass is to be used, the exchangeable bases introduced maybe specific catalysts, they maybe stabilizers, or they may be stabilizer promoters. They may be introducedas simple ions or as complex ions, and may enhance the catalytic activity of the final contact mass, improve its physical strength, or both.

As has been described above, base exchange bodies can be caused to react with compounds containing acidic radicals capable of forming therewith salt-like bodies. The radicals may be present in the form of simple acid radicals, polyacid radicals or complex acid radicals, and include radicals containing the following elements :-chromium,' vanadium, tungsten, uranium, molybdenum, manganese, tantalum, niobium, antimony, selenium, tel lurium, phosphorus, bismuth, tin, chlorine, platinum, boron. "Among the complex radicals are ferro and ferricyanogen, certain ammonia complexes and the like. The amount of acid radicals caused to unite with the base exchange bodies to form salt-like bodies may be varied so that the resulting products may possess the character of acid, neutral or basic salts. Most of these acid radicals are stabilizers or stabilizer promoters for the catalytic reduction and hydrogenation of carbonyl compounds-to various oxygenated an'd hydrocarbon products.

' The base exchange bodies diluted or undiv i luted, or some of their salt-likebody derivatives, may be treated with acids, such as min eral acids, for example, 240% sulfuric, hydrochloric or nitric acids, to remove part or all of the exchangeable bases, or also part or all of the basic portion of the nucleus.

In the case of zeolites, the partial leaching with acids, which leaves part or all of the basic portion of the nucleus or even part of the exchangeable bases, does not aflect the functionof-the zeolitesas catal sts when they contain catalytically active e ements in the basic portion of the nucleus, or in some cases even exchangeable bases, and such partially leached catalysts are of great importance in many reactions. Where the leaching is carried out to completion the advantageous of the two, and usually will not be a specific catalyst for the reduction or hydrogenation of oxides of carbon. It serves, however, as an advantageous physical carrier of specific catalysts, and in the case of partiall substituted zeolites may also contain sta ilizer promoters.

Leached non-silicious base exchange bodies, either partially or completely leached, may contain catalytically actlve components and behave as catalysts, stabilizer promoters or both, and many important catalysts for the reduction and hydrogenation of carbonyl com )ounds are thus obtained. This is particl arly the case for reactions where a relatively alkali-free contact mass is required for best results and where the alkali content of a. contact mass containing a base exchange body may be too great for optimum results.

Base exchan e bodies or their derivatives, diluted or undiluted, ma also be coated in the form of films on massive carrier granules "or may be impregnated therein. The massive carriers may be inert, actlvatmg, or

their relatively high heat conductivity tends to prevent local overheating in highly exothermic reductions or hydrogenations' of car-,

bonyl compounds, which is of considerable" importance in obtaining good 'elds, as many of the reactions, particular y hydrogena tions, are equilibrium reactions, and at higher temperatures hydrogenation catalysts reverse their function and tend to favor dehydrogenation with resultin lowering of yields and contamination of t 0 product.

.,.,The pment invention is applicable to all reductions and hydrogenations of carbonyl com unds in which at least part of the reductlon is efiected on the carbonyl group. One of the most important series of reductions and hydrogenation's consists in the reduction or ydrogenation of oxides of carbon, such as carbon monoxide, carbon diox ide, and the like. These compounds can be reduced in the vapor base by means of the contact mams descrl above containing rmutogenetic bodies to various products sation catalysts such as for example alkalis,

' components such as alkalmestabilizers that when strong reduction or hydrogenation catalysts suchas'cobalt, nickel, iron, etc., are present the tendency is to produce methane, especially in .the presence of dehydration stabilizer promoters. Under somewhat different reaction conditions, and particularly in the presence of contact'masses which have favor condensation the tendency is to produce higher alcohols,ketones and hydrocar- 'hyde to the correspondin bons, many of them being of petroleum like character, especially when a large amount of strong alkalies are present in the contact mass, and most of'the products are useful for motor fuels either with or without subsequent refining. Where there is insufficient hydrogen present organic acids such ,as propionic and buty'ric acids may be produced. Other carbonyl compounds may be reduced, example, ketones to-secondary alcohols, an important example of which is the reduction of acetone; to isopropyl alcohol, methylethyl ketone to secondary butyl alcohol, and the like. Aldehydes may be reduced to primary alcohols, with or without hydrogenation in the case of unsaturated aldehydes, such as acetaldehyde to ethyl alcohol, crotonaldehyde to butyl alcohol, valeraldeg alcohol, benzaldehyde to benzyl alcohol, etc.

Esters may be reduced to aldehydes and alcoholsor to alcohols alone, thus for example, phthalid, the inner ester of methoxybenzoic acid to benzaldehyde or benzyl alcohol, etc.

Acids may be reduced to inner esters, in the case of polybasic acids, or alcohols. Thus phthalic anhydride may be reduced to phthalid or to benzaldehyde or benzyl alcohol, depending on reaction conditions and on the presence or absence ofstabilizer promoters favoring the splitting of! of carbon dioxide. Camphoric acid can be reduced-to alphacam-. pholid, etc. vQuinones, such as a-nthraquinone, benzoquinone, etc., can be reduced to the corresponding hydroxy compounds.

In addition to reactionsin which a more or lesshomogenous raw material is-reduced certain mixtures of raw materials may be ef-- fectively reduced with or withoutthe. presence of additional reducing gases. Thus for,

example, oxides of carbon may belreduced in the presence'of' the vapors many organic compounds. For example, they may be reduced in the presence of aliphatic hydrocarbons, such. as parafiins, olefines, acetylenes, hydrocarbons having the formulaC H C H IL etc. Hydrogen may be-present or absent,and the class of products obtained,- such as mixtures of oxygenated compounds,

or in many cases oils which are predominately hydrocarbon in their nature, will vary with the amount of the reacting ingredients and with the contact masses and reaction conditions used, and it is an advantage of the present invention. that these novel combined reductions can be carried out in the desired direction with great effectiveness by the in-' corporation of suitable stabilizer promoters or stabilizers in the contact masses.

Another class of combined reaction consists in the reduction of oxides of carbon with or without hydrogen in the presence ofvapors of aliphatic alcohols, such'as paraflin alcohols having the formula C H OH, or unhaving the formula Oxidation products of alcohols, such as for I example, saturated or unsaturated aldehydes and ketones, or oxidation products ofpclyvalent alcohols, such as glycolaldehydes,

,e'lyoxcal glyoxcyclic' acid, oxalic acid, and the like, may be used for vapor phase reductions in the presence of oxides of carbon and hydrogen. Oxidation products of trivalent alcohols and divalent isomeric alcohols may also be used, of course only where it is possible to obtain the vapors of the compounds without undesired decomposition.

.Aliphatic acids-form another important class of compoundswhich can be reduced in combination with oxides of carbon. The acids. include fatty acids, oxyacids, lactones, polybasic acids, ketone acids; and .the like. Other miscellaneous aliphatic carbonyl compounds such as aldehyde alcohols, diketones', triketones, oxymethylene ketones, ketone aldehydes, ketone alcohols and the like, may also be combined with oxides of carbon and reduced in the presence of the contact masses described above to form'many valuable products. a

In addition to compounds of the aliphatic series which may be reduced together with oxides of carbon, various compounds of the cyclicseries, such as for example, alicyclic compounds, for instance, cycloparafiins, cy-

clo-olefines, cyclodiolefines, may be combined with oxides of carbon and reduced. Examples of specific "members of this class are .cyclohexane, cyclopentadiene, dicyolopentadiene, and the like. Of course alicyclicar-. bonyl compounds, such as cyclohexanol,

cyclohexanone, etc., may be used, it being understood inthis connection and throughout the specification that any compound contaming the CO group, irrespective of whether the oxygen is united to carbon with a single ora double bond, are included under the term car'- bonyl compounds.

Aromatic compounds such as benzene hydrocarbons naphthalenes, anthracenes, phenanthrenes, phenols, aromatic alcohols, aldehydes, ketones and acids may be reduced in the presence of oxides of carbon and hydrogen, of course only insofar as the products are capable of volatilization without undesired decomposition.

Heterocycliccompounds, such as products containing the furane nucleus, pyrrole bodies, pyrrolidines and the like, may be reduced together with oxides of carbon by means of the contact masses described in the present invention.

A number of combined reductions have been referred to briefly above, but it should be understood that other combined reductions are included in the scope of the present invention and that compounds belonging to more than one of the above enumerated groups may be simultaneously reduced with oxides of carbon.

In carrying out these complicated syntheses the permutogenetic contact masses will usually include not only reduction catalytic components and hydrogenation catalytic components but the most various types of stabilizer promoters, such as oxidation catalysts, catalysts for splitting off water, carbon dioxide or both, catalysts capable of introducing the elements of water into unsaturated hydrocarbons, catalysts which favor the production of ethers, esters, acetals and the like, condensation' catalysts, catalysts which favor intramolecular re-arraigement, polymerization catalysts and the like.

The invention willbe described in detail in connection with the following specific examples which illustrate a few of the many reductions of carbonyl compounds which fall within the scope of the present invention. Throughout the specific examples, as in the introductory portion of the specification, the expression carbonyl compounds will be used in a somewhat broader sense than is sometimes current, and will. include phenols, alcohols 31nd similar compounds in which oxygen is not attached to carbon by means dehydrogenationcorporation of all of the above referred to diluents the mixture just remains easily stirrable, A saturated solution of sodium aluminate containing 10 parts of A1 0 is then stirred into the suspension, or if desired the aluminate can be replaced partly or wholly by corresponding amounts of cadmiate or zincate solutions or mixtures of the two. I'he suspension is then treated with 25-30% solution containing 15 parts of copper nitrate with 3 mols of water and 20 parts of a saturated solution of chromium nitrate. A baseexchange body prec-ipitates,whi'ch is separated and washed in the usual manner, followed by drying at temperatures below 100 (3., whereupon the mass is submitted to the action of a wet atmosphere for some time and then put on a filter and hydrated by trickling water over it. After hydration the base exchange body while still moist is pressed into suitable tablets in a pill making machine and again dried. If desired the chromium nitrate solution may be replaced partly or wholly by equivalent solutions of zirconium nitrate, zinc nitrate, cadmium nitrate, or a mixture of two or more of'them.

The contact mass obtained is placed in a high pressure converter, especially a converter provided with double counter-current automatic heat exchange devices, and is then reduced with hydrogen or water gas or other suitable hydrogen containing gases at about 300 C. After reduction is complete the contact mass can beeifectively used for the synthesis of methanol with the concomitant production of higher alcohols and ketones by reducing oxides of carbon such as carbon monoxide, carbon dioxide or a mixture, which are passed over the contact mass in the circulatory process in the presence of hydrogen, which should be in excess of the theoretical amount required. The synthesis should preferably be carried out at about 300.370 C. and under from 80-150 atmospheres pressure. The reaction product contains methanol together with a major proportion of higher alcohols and some other oxygenated compounds. After the gases have left the con-i verter they are condensed before recircu- Of a double bond, but the invention does not; lating, in order to remove the condensable include hydrogenations of such compounds as phenol and the like, where none of the reaction takes place within the carbonyl group, and such hydrogenations are specifically disclaimed.

E'wam-plc 1 A contact mass is prepared as follows 2- 40-50 parts of SiO, in the form of a diluted sodium waterglass solution are mixed with parts of monazite sand refuse, 50 parts of glaucosil (the acid treated residue of greensand) and 50 parts of copper ore, such as malachite. The dilution of the waterglass solution should be suflicient so thatafter inproducts produced. The composition of the remaining gases is then again adjusted to initial conditions and recirculated through the converter. Inert gases such as nitrogen, the rare gases of the air, methane. and the like, mayaccumulate, and should be vented, either continuously or at suitable intervals, preferably through a vent tower provided (with a sufiiciently effective absorption system to prevent large losses of the reaction products. The gas speed for the synthesis of the alcohols, ketones and other oxygen containing products should preferably be high, and a gas speed of from 80-150 times the converter volume per hour may be considered as normal.

If it is desired to produce methanol in larger proportion the contact mass should be toned, which may be effected as follows After the base exchange body has been bydrated it is leached with acids, such as 245% hydrochloric or nitric acid, in order to partly remove the exchangeable alkali fromthe base exchange molecule. The leaching process is to a certain extent empirical, and it is best to test samples, to determine when the alkali has been sufficiently leached out to produce the desired effect. In general the leaching should be continued until the alkali content of the base exchange body has been reduced to from 20-30% of the original amount present. After the leaching treatment the contact mass is washed with water to remove the last traces of the acid used, and then after suitable reduction forms a very eflicient contact'mass for the synthesis of methyl alcohol from oxides of carbon and hydrogen, the latter preferably being in excess. The mixture is passed over the contact mass at 250-; 350 C. under a pressure of 80-250 atmospheres,the process being a'continuous circulatory process and the meth l alcohol be ing removed by condensation rom the gases before recirculation. Methyl alcohol of a high purity is obtained, and may be separated out by cooling or'by absorption. The lower the alkali content of the base exchangebody after leaching, the purer the methyLalcohol will be, in accordance with the above mentioned actionof alkali as a condensation catalyst, for it is probable that when alkali is present a considerable amount of the methyl alcohol either condenses with itself or with other reaction products in a nascent state, such as for example formaldehyde. The extremely favorable hysical structure and catalytic properties 0 the contact mass results in high efliciency.

Example 2 100 parts of a natural or artificial z eolite,

the latter prepared either by wet or fusion tion or a mixture of both, with or without man anese salts, to effect a maximum of base" exchange. Other bases which may be present in the form ofsalts are zirconium, cerium,

silver, copper or gold. Copper is particularly effective and should preferabl alwa s be at least one of the components. t is a vantageous to replace a maximum. of the exchangeable alkali and for this reason it" is desirable-to choose zeolitesofzhigh base exchanging ow rs such as for example, thoseof the alumin silicate type-,in which, however, the aluminum maybe replaced partly or wholly by zinc or cadmium. v

The base exchange body obtained after introducing the catalyticafly effective exchangeable bases may be used for the synthe-,

sis of oxygen containing organic compounds from oxides of carbon and hydrogen or other reducing gases. The contact mass may be further toned to enhance the specific efiiciency by treating it with solutions of salts of the metal acids of the fifth and sixth groups-of the periodic system, such as vanadium, chro: mium, molybdenum, and the like, in order to produce the so called salt like bodies. This may, for example, be effected by trickling a 1% ammonium vanadate or a corresponding salt solution over the contact mass and then washing the salt like body obtained. The

alkali left in the base exchange body is neutralized sufliciently by this procedure, anddoes not have any harmful effect in the synthesis; But when large amounts of alkali remain the reaction should be carried out at somewhat higher temperatures, such as for example, 300-450 C. It is sometimes advantageous to leach out part or all'of the alkali-which is not replaced by the other bases. Preferably very'dilute-inorga-nic acids should be used as leaching agents, in order to prevent destruction of the excellent physical. propertiesof I the complex contact mass. 9

When the same concentration of gases is used with leached contact masses at tempera- Y tures from 300-450 C. and under a pressure Example 3 In forming a contact mass the following solutions are prepared (1). -95 parts of SiO in the form of a .dilute sodium or potassium waterglass' solution are mixed with 200-300 parts of kieselguhr, pulverized quartz, or asbestos powder, the amount of dilution being sufficient so that after all'of the diluent is incorporated the mixture just remains readily stirrable.

, (2) 30 parts of zinc nitrate with 6 mols of water,-or any othen corresponding zinc salt, are dissolved in 2 N caustic potash to form the corresponding potassium zincate,

preferably by first precipitating zinc hydroxide and then dissolving it up in the potassiumhydroxide. The zinc may be re-' placed with a corfiesponding amount of cadmium or aluminum, or a mixture may be used.

(3) 10 arts of freshly precipitated chromiumhyroxide are treated with 'suflicient 2 N potassium hydroxide solution to form the corresponding potassium'chr'omite.

'(4) 8-9 parts of lead nitrate are dissolved in sufiicient 2 N potassium hydroxide or sodium hydroxide to folm the corresponding potassium or sodium plumbites.

ous agitation, whereupon the mixture'is warmed to 50- 60 C. and, solidifies to a gel,

' .nolphthalein results.

which is separated by pressing off the mother liquor in the usual manner and is then thoroughly washed and dried. If necessary, the

yield may be increased by'the addition of sufiicient dilute mineral acids, such as nitric or hydrochloric acid, with vigorous agitation until a slight alkalinity or neutrality to phe- The product is dried preferably at temperatures under 100 ,L, is hydrated with water and again dried. The resulting contact mass 'is treated for several hours at 300-400 C. with water gas mixtures under a pressure of 50-200 atmospheres. After this reduction the contact mass may be used for the reduction of oxides of carbon to oxygen coutainingcompounds. Depending on the reaction conditions, the main roduct may be methanol with larger or smaller amounts of higher alcohols, such as propyl alcohol, isopropyl alcohol, butylalcohol, isobutyl alcohol, isoamyl alcohol, aldehydes such as isobutyraldehyde, valeraldeh deand the corresponding symmetric an asymmetric ketones. Some acids, such as aliphatic acids, may also be obtained. Preferably carbon monoxide or carbon dioxide or a mixture,

together with 4-10 times the theoretical gases. The temperature should be between 300450 C. In carrying out these syntheses the converter should preferably be provided with automatic double counter-current heat exchange elements to control the exotherm of the reaction andtoimprove the heat economy. The converter materials should of course be such as are unattacked by carbon monoxide and hydrogen. Preferably the outer shell of the converter may be made from special steels,

such as chrome or vanadium steel, as used in converters for the synthesis of ammonia. The internal double counter-curreht heat exchange elements may advantageously 'be made from aluminum, silver or copper, or

may be coated with. these materials, or they maybe made from alloys of steels which contain molybdenum, vanadium, tungsten,

manganese or chromium, if necessary com-- "bined with copper, silver or aluminum;

The yield may be improved by exchanging part of the-potassium of the base exchange body for cerium, manganese, calcium, magnesium, aluminum, zirconium, cadmium, chromium, silver, co per, barium, or strontium, or a mixture, t e base exchange being effected by trickling 3-10% solution of the corresponding water soluble salts ofthe above mentioned elements over the'base exchange '-body.

After partial replacement of the alkali of the base exchange body by other basesthe contact mass may, if desired,'be treated with salts of the metal acids of the fifth and sixth groups of the periodic system, such as ammonium vanadate, ammonium chromate or ammonium molybdate, singly or in admixture, in order to produce the so called salt like bodies. If desired the base exchange bodies may also be leached to remove part or all of the exchangeable alkali by means of dilute mineral acids, and such leached base exchange bodies aid in producing methanol of high purity. A 23% h drochloric acid or nitric acid solution may e ectively be used for such leachings, the remaining. acid of course being carefully washed out afterthe treatment is completed. The base exchange bodies may also be more highly diluted with relatively inert material, in order to spread the reaction over a larger contact space.

EmampZe 4 40-45 parts of SiO in the form of a. dilute waterglass solution are treated with about a 10% potassium chromite solution containing 22 parts of chromium nitrate with 9 mols of water. An approximately 10% ferrous nitrate solution is permitted to run intothe 'mixture with,vigorous agitation until the whole mass shows only a slight alkalinity to phenolphthalein. A gelatinous product is formed, separated from the mother liquor 1n the usual manner, and dried preferably at.

temperatures below 100 C. It constitutes a potassium chromium-ferrous base exchange body-which may then be reduced in a stream of hydrogen containing gases at 300 C.

Prior to the reduction the exchangeable alkali may be replaced by alkaline earth metal salts. The contact mass=after reduction is well suited for the production of hydrocarbons of petroleum like nature, well suited as as motor fuel when purified water gas is passed over the contact mass under pressure at 300-350 C..

It is also possible to efiect the synthesis of these petroleum like h drocarbons inintermediate stages. Thus or example, methanol may first be formedin the presence of a layer of specific methanol catalyst and then a layer of motor fuel catalyst may follow. 1

The catalysts for the intermediate steps may ust remains stirrable.

Emapze .5

m A non-silicious base exchange body is prepared as follows:

. 3O parts'of zinc nitrate containing 6 mols of waterare dissolved in 100 partsof water and transformed into the potassium zincate by means of 10 N caustic potash. parts of cadmium nitrate with 4 mols of water are dissolved in 200 parts of water and transformed into the corresponding potassium cadmiate by means of 10 N potassium bydroxide solution. A sodium aluminate-solution is prepared by recipitating aluminum hydroxide correspon ing to 10part's of A1 0 from a solution of an aluminum salt b means ofammonia, thoroughly washing an transforming the freshly precipitated product into sodium aluminate by meansof a 2 N sodium hydroxide solution. The metallates are mixed together, and asbestos powder or umicemeal is stirred in until the mixture A solution containmg 45 parts of ferric nitrate with 9 mols-of water. dissolved in 450 parts of water is then added to the suspension in a thin stream with vigorous agitation. The reaction roduct is a non-silicious base exchange ody, which is ressed, dried at 1009C. and,reduced'in t e converter system at 300 C. in a stream of 'hydrogen' or hydrogen containing gases. The reduction should be carried outcautiously, preferably diluting the hy-' drogen containing gases with indiflerent gases, such as nitrogen, in order to efiect' a smooth, well toned reduction of the complex molecule. In some cases it is desirable 45 to carry out the reduction in the presence of steam. i' k i The contact mass after reduction may be used for the production of methanol orpetroleum like bodies-from oxides of carbon,- with -or without'hydrogen containing gases,

water gas, water gas and h drogen, or water gas and methane are'use as the raw materials. On fractional distillation of the liquid product petroleum like bodies are obtained ina fractionv boiling from 90'-O.,

while the higher fractions are mainly esters or'alcohols, such as propyl alcohol, butyl alcohol, and the like..' The catalytic effectiveness of the mass can be materially increasedby using catalyticallyplfective bodies as .diluents, such as for example, salts of the metal acids, of the fifth and sixth groups of the periodic system, as iron vanadate, copper f vanadate, silverxvanadate, cobalt vanadate, nickel vanadate, bismuth vanadate, strontium vanadate, calcium vanadate, magnesium vanadate, beryllium vanadate, barium vanadate, cadmium vanadate, zinc vanadate, cerium vanadate, manganese vanadate or chromium vanadate, singly or in admixture. Correspondmg salts of molybdlc, tantallc, chromlc,

uranic or tungst'ic acid canbe used, with or without vanadates, singl efi'ective or stabilizer promoter components or in admixture; Another method of intro ucing catalytically consists in using the salts or oxides diluted or undiluted, partihularly oxides precipitated on colloidal silica or glaucosil. These oxides may be iron oxide, cobalt oxide, nickel oxide,

- manganese oxide, copper oxide, silver oxide,

calcium oxide, tin oxide, ccrium'oxide, lead oxide or bismuth oxlde, wlth or without alkaline earths, or' rare earths. 'Catalytically active natural products such as oreslggf: ex-

ample, iron ore or copper ore, may lso' be used as diluents in the permutogenetic A particularly efiective diluent for t e synthesis of higher alcohols, ketones, aliphatic acids and heavier oils is'the residue obtained from the distillation of various kinds of oil shale, which may dies.

be considered as natural catalytic compositions. These residues are f eifective for the synthesis of hydrocarbons of petroleum or gasoline like nature. Analyses 1 CaO,'MgO, K 0 and Na O. Other elements show that the residue contains SiOg, Fe Oa,

may-also be present in small quantities,'depending on the origin ofthe oil shale. In order to getthe-most effective residue it is advantageous to distill off the oils and gases mixed with other organic materials, such asf from the shale at gradually. increasing temthe vapors of methyl alcohol, ethyl alcohol, methyl formate, methane, ethylene and the like. Oxygen containing organic compounds 55 are produced under pressure, with or withoutrecirculation. When petroleum like bodies are desired a recirculatory process should be used, or the reacting gases should'be passed through a series ofconverters in order to exhaust them. .This, method is. effective especially where themethane which is produced as a by-product-can beeflectively'utilized. The synthesis of liquid reduction products should take place at temperatures between 220400 0., and a mixture is obtained when pcratures in" order to produce a voluminous residue. Good results are 150 obtained when residues are prepared b distillation with superheated steam. or by destructive distillation in a vacuum. As a raw material car-. bon monoxide or carbon dioxide and hydro: gen maybe used in the presence or absence of other hydrogen containing vapors or: 125

gases, such as methane, ethylene, methyl alcool, propyl alcohol, and the like. The hydrogen content ma be in excess of the content of oxidesof car on} or vice versa- When gases obtained in crackin proceses, for example, tail gases, or from t e distillaiao - Excellent carbons are obtained in addition to methyl alcohol. In order to favor the production of petroleum like bodies or paraflins, the syntheses may also be carried out at low pressure, or without pressure, the most favorable temperatures lying between 200-350" C.

' Example 6 Methane canbe effectively produced from oxides of carbon by means 0f contact masses containing permutogenetic bodies, especially where the reaction is carried out'in converters which do not permit accumulation of heat, as for example, converters provided with automatic double counter-current heat exchange elcments. A contact mass for the production of methane may be prepared as follows:

24-30 parts of SiO in. the form of a commercial sodium waterglass solution are di-' luted with 6-7 volumes of water and suflicient kieselguhr, pumice meal or quartz powder isadded so that the mixture just remains readily stirrable. Ten parts of nickel nitrate with 6 mols of water are dissolved to a 2 N' solution and mixed with an aluminum chloride solution of the same concentration containing aluminum corresponding to 2.5 parts of A1 0 The mixture is then added to the waterglass suspension with vigorous agitation, until the reaction product and the mother liquor react slightly alkaline or neutral to phenolphthaleln. gel is pressed from the mother liquor, washed two or three times with an amount of water about equal to three times the volume of mother liquor, and then dried in theusual manner, hydrating with water if necessary and; breaking into small fragments. If the kernels show insuflicient strength it may be desirable to wash them before drying with a dilute sodium waterglass' solution to effect surface silicification. then filled into aconverter system and reduced with water gas or other h drogen conarbon montaining gases at200-300 C. oxide or carbon dioxide, or a mixture, with hydrogen or hydrogen containing gases are passed over the contact mass at 300-350 C- yields of methane are produced, present to permit the reaction to be carried out.

when suflicient hydrogen is .Ewamplc 7 Contact masses 'con aining two-component zeolites are highly effective for the-production of methane, methanol and higheralcoike bodies, or petroleum or gasoline like bodies from oxides of carbon and hydrogen,

The precipitated The contact mass issuch as water gas. Contact masses of the aluminum double silicate or. aluminosilicate types may be prepared and effectively used. An example is the followingz, i

100 parts of finely ground pumice meal are impregnated with 15- 0 parts of copper nitrate in solution, and this is then treated with 10% alkali solution to precipitate out copper hydroxide in a state of fine subdivision throughout the pumice meal. The mixture is then mixed with a. waterglass solution containing 240-300 parts of SiO and diluted with sufiicient water, so that it forms with the impregnated pumice meal an easily stirrable suspension. A 10% potassium aluminate solution is prepared from aluminum hydrox ide freshly precipitated from aluminum salt solutions,thealuminum content being equivacourse an aluminum salt solution can be employed. In this case, however, the base exchange body will of course be of the aluminum double silicate type. The precipitate obtained is pressed, washed moderately, dried, and then hydrated by trickling water over it, which results in the removal of excess alkali. The cake is then again dried and broken into fragments suitable for catalysis. The fragments are reduced with gases containing hydrogen at 200-320 0., and result in a contact mass which can beused for the preparation of higher alcohols and other oxygen containing organic compounds from carbon monoxide or carbon dioxide mixed with an excess of hydrogen. The reaction temperatures for favorable results should be between (l450 C., and high pressure with or without recirculation is of advantage. The upper pressure limit is determined solely by the strength of the apparatus used.

The aluminum in the zeplite may be substituted partly or wholly by one or more of the following elements :cadmium, zinc, zir-- conium, tin, lead, chromium. Vanadyl compo'unds'may also be used. Contact masses containing iron, nickel or cobalt favor the formation of methane, .parafiins or petroleum possible of catalytically effective components in the desirable physical framework of the base exchange molecule. Examples of such heavy metals are iron, cobalt, manganese,

chromium, zirconium, tin, cerium, lead, thorium, etc. The contact masses can be further toned by treating the base exchange bodies with compounds containing the metal acid radicals of the fifth and sixth groups of the periodic system, in order to form the so called 5 salt like bodies. Contact masses in which the exchangeable alkali is replaced to a great extent by copper, zinc, cadmium, chromium, titanium, zirconium, tin, cerium, lead, ,gold or silver favor the production of methanol, as do those which form salt like bodies with the metal acid radicals of the fifth and sixth groups of the periodic system. These salt like bodies also show an enhanced resistance to high temperatures. If desired, permutogenetic bodies maybe leached instead of subjected to base exchange, and in this manner contact masses are obtained which are well suited for the production of very pure meth-.

Combined reductions of oxides of carbon and other organic compounds such as have been described in the introductory portion of the specification may be carried out effectively by means of contact masses containing permutogenetic bodies, and it is an advantage that a number of catalytically active components and stabilizer promoter components can be united in a single chemical compound wherever this is desirable. Great freedom of action and, range of components is thereby achieved. An example of such a contact mass is prepared as follows:

10 parts of zinc hydroxide, freshly precipitated from any zinc salt solution, are transformed into the corresponding potassium z-incate by means of a 2 N potassium hydroxide solution. The zincate solution is prepared by transforming 15 parts of fresh- 1y precipitated cadmium hydroxide into p0- tassium cadmiate by means of a 2 N potassium hydroxide solution. To the mixture of the two metallate solutions, 20 parts of col.- loidal silica or finely activated powdered car bon are added and thoroughly mixed. Thereupon a 510% zirconium nitrate solution containing 40-50 parts of zirconium nitrate with 5 mols of water are added to the metallate suspension with vigorous agitation until the mixture remains slightly alkaline to phenolphthalein. A precipitate is obtained consisting of a non-silicious base exchange body which contains zinc, cadmium and zirconium in non-exchangeable form. The reaction product is freed from the mother liquor in the usual manner and after pressing out the last portions of the mother liquor, is dried, preferably at temperatures below 100 C.

The mass thus obtained is impregnated by mixed with a potassium cadmiate solution trickling a 1% ammonium vanadate solution v of very favorable physical characteristics.

The hydrogenation catalysts are the zinc and cadmium which may also be replaced by other amphoteric metal oxides of mildreducing activity such as lead and The zirconium may be considered as a dehydrogenation o'r condensation catalyst, and may be replaced partly or wholly by thorium, titanium, aluminum, chromium, or trior tetravalent vanadium. Other dehydrogenation catalysts may, also be present.

The vanadate is an oxidation catalyst, and of course may be substituted by other acid radicals of the metals of the fifth and sixth groups of the periodic system, such as tantalum, bismuth, chromium, molybdenum, tungsten, or uranium, singly or in admixture.

Other combinations of components are'possible. Thus for example, the hydrogenation catalysts may be introduced in the form of metal salts, or dehydrogenation catalysts maybe introduced as metallates, or either or lnutogenetic bodies. It be apparent that I some of these diluents are combined catalysts and stabilizer promoters, as for example, copper vanadate,'or others such as aluminum vanadate or zirconium vanadate, contain two different stabilizer promoter components, one being a dehydrogenation or condensation catalyst and the other an oxidation catalyst. The molybdates, tungstates or uranates can be used in place of the vanadates or mixtures may be used. Minerals containing one or more of the above enumerated elements also are excellent diluent materials.

The contact mass compositions described above are well suited for the synthesis of organic compounds from. oxides of carbon and hydrogen admixed withorganic compounds, such as for example, saturated alcohols C Hg OH such as methyl, ethyl, or propyl alcohols, or unsaturated alcohols of the general formulasCnH2n-1OH, C H OH, etc. Ethers and esters, such as methyl formate, saturated and unsaturated aldehydes and ketones, etc., aliphatic acids, such as the fatty acids, polyvalent alcohols or oxidation products of polyvalent alcohols and related compounds, polyvalent acids and relat-- ed compounds, such as oxyacids, inner esters, such as phthalid and similar compounds, may be present, as described in the introductory portion of the specification. An example of such a mixture is a gas containing 5% methanol, 3% ethanol, CO, hydrogen and 2% nitrogen. When this mixture is passed overone of-the above described contact masses in a high pressure converter, preferably provided with automatic heat exchangeelements, at "350-.-420 C., under a pressure of 180-250 atmospheres, a more or less complex mixture of reaction products is produced which contains pro'pyl alcohol, isobutyl alcohol,'a1nyl alcohol, and smaller quantities of higher alcohols and esters of these alcohols-with aliphatic acids, such as acetic, propionic, etc., methyl formate, and ketones corresponding to the alcohols; The mixture may be used as such for some purposes or it may be separated into its constituents by suitable methods. Y s

increase in the carbbnmonoxide content will result in an increased proportion of free acids and ketones. It will be 'clear that instead of the artificial mixture of carbon monoxide and hydrogen, water gas can be used. In some cases the presence of water vapor is also favorable. The pressures mentioned above should not be considered as limiting the invention, as the maximum pressure is dependent only on the apparatus available. Preferably the syntheses are carried out in a closed circuit or else in a seriesof converters in order to exhaust the reaction components. Exhaust gases may be used for illuminating gas or for other syntheses of organic compounds using similar permutegenetic contact masses. When the mixture is varied, particularly when the content of hydrogen is increased, high molecular oils can be obtained, and if the amount of alkali in the contact mass is high, considerable amounts of petroleum-like bodies are obtained.

When a less complex mixture ofreaetion products is desired, especially whenalcohols are to be obtained, the base exchange bodies may be leached in order to eliminate partly or entirely the exchangeable alkali content, nd on, the other 'hand the addition of a arger amount of alkali particularly K 0, favors the production of oils, as will an increased proportion of hydrogenation contact masses. Suchn'eactions may be carried out atmuch lower pressure. The K 0, appears to act both as a stabilizer and asa condensation catalyst in these reactions Instead of using a single contact mass the gases may be passed over a-layer of methanol catalyst, in order to obtain the methanol percentage in the vapor mixture, and the partly reacted gases may then be passed over one of the contact masses described above.

Example 9 The following contact mass is prepared:

4 parts of Al O +3H O, freshly precipitatcd from any aluminum salt solution, are transformed into the corresponding aluminate by means of a 2 N potassium hydroxide or' sodium hydroxide solution.

15 parts offreshly precipitated cadmium hydroxide are also transformed into the corresponding potassium cadmiate in the usual 7 manner.

16 parts of hydrated V 0 are dissolved in 10 N sodium hydroxide solutionto form sodium vanadite.

Finally, 2.5 parts ofzinc hydroxide are dissolved in a 2 N sodium hydroxide solution to produce sodium zincate.

These metallate solutions are then mixed together, and a non-siliceous base exchange body is precipitated by the help of salt solutions containing zirconium, titanium, thorium, manganese, and tin in equimolecular proportions. The solution may advantageously be of about 10% strength, and is added with vigorous agitation until the reaction product is neutral or slightly alkaline to phenolphthalein. The resulting product is freed from the mother liquor, dried, hydrated by trickling water over it, and impregnated with a 10% ammonium mctatungstate solution after hydration. A second drying fol lows, and the dried product is then carefully leached with about a 5% dilute nitric acid solution in order to eliminate amaximum of alkali. is results in a considerable loss of mechanical strength of the contact mass kernels, and in order to provide for a satisfactory mechanical strength they may be mixed with a natural gum, dried, and broken into suitable pieces. This contact mass can be used for the synthesis of alcohols and liquid hydrocarbons, using as a raw material.

ides of carbon and hydrogen containing gas 7 such as water gas. A specific gas composit 1on is 20% ethylene or its-homologues, 10% carbon monoxide, 65% hydrogen and 5% ni: trogen. Other gases which do not have a deleterious eflect on the contact mass,-sdch as carbon dioxide or Water vapor, are in some cases advantageous. The gas mixture is passed over the contact mass at 300400 (1.,

at 80-160 atmos heres. Low boiling liquid hydrocarbons o petroleum-like nature are obtained, the main fraction goi over at 65 (3., and possessing a s ci e gravity of 0.7 3 to 0.74 at 20 C. Sma l quantlties of alcohols, aldehydes, and ketones are obtained as by-products.

When phenolic bodies are present, they are for the most part transformed into aromatic hydrocarbons. Thus for example, phenol is transformed for the most part into'benzene. These syntheses can be carried out in a closed circuit or in a series of converters, and it is an advantage of the process that the contact mass does not favor the decomposition of carbon. Instead of the'specific mixture referred to above, hydrocarbon mixtures, es-

- The different contact masses may be arranged 1n zones or layers, or mixed together. When recirculation in a closed circuit is used the lntrod-uction of the fresh gases may be effected so as to maintain a fairly constant.

composition, but. this is not really essential,

and-the adjustment of composition ma be approximate. In some cases a very mar edly decreased pressure may be utilized.

When it is desired to completely avoid the formation of'alcohols and esters, it is advantageous to include iron, cobalt and manganese in the contact mass, and the pressure should also be reatly reduced, and the reaction may even be carried out at atmospheric pressure.

y When the catalytic efliciency of such con- I tact masses becomes weakened the may be regenerated by treating them wit oxygen containing gases at 380450 C., and after the oxidation is complete the contact mass can be again reduced with hydrogen containing gases, such as water gas, whereupon its effectiveness is renewed.

Etample 10 troleum may be so treated. These combined methods of synthesis may be carried out in 'gas stream. 'If air is a plurality of converters, the first being provided with oxidation catalysts and small amounts of oxygen being introduced into the d the nitrogen remaining after the synthesis is completed may be used for the synthetic production of ammonia. This incomplete combustion may be also effected by the so-called surface combustion methods.- The-contact mass for the partial oxidation of such hydrocarbon mixtures may be prepared as follows:

210 parts of. 33 B. potassium-waterglass V solution'diluted with 6-8 volumes of water are mixed with sufiicient finely divided kieselguhr so that the suspension just remains easily stirrable. To this mixturea potassium vanadite solution is added which may be prepared'by reducing 18 parts of V 0 in 250 volumes of water at an elevated temperature with sulfur dioxide in the presence of dilute sulfuric acid, decomposing the blue vanadyl sulfate obtained with alkali, and transforming the V 0 precipitated into a coffee-brown" solution'of potassium vanadite with just suflicient 5 N caustic potash solution, To the mixture of waterglass and vanadite a 10% aluminum sulfate solution is added in a thin stream with vigorous agitation until the reaction mixture is neutral or just alkaline to phenolphthaleins The mass solidifies to a dirt green gel, which is filtered with suction,

was ed slightly and dried. Other metal salt solutions may replace the aluminum partly or Wholly, especially solutions of salts of am photeric metals, such as iron sulfate, zirconipartially oxidized audit may then be directly used for the synthesis of alcohols'or other oxygenated compounds or hydrocarbons using one or other of .the contact masses described in the foregoing examples.

Other contact masses containing metal elements of the fifth and sixth groups of the periodic system are well suited for the partial oxidation of the hydrocarbons, and these contact masses may be toned by stabilizers or stabilizer promoters.

A combination of oxidation catalysts, water gas catalysts and catalysts for the synthesis of oxygenated'organic compounds or hydro carbons is also effective, the water obtained in the catalysts being used in the water gas catalysis and the mixture of gases thus obtained being well suited for the specific syntheses of the present invention. i

I claim:

1. A method of catalytically reducing carbonyl compounds which comprises causing ence of a contact mass containing a permutogenetic body and also containing at least one substance selected from the group consisting of dehydration catalysts, dehydrogenation catalysts, oxidation catalysts, dehydration catalysts.

4. A method of catalytically reducing carbonyl compounds which comprises causing them to react with reducing gases in the presence of a contact mass containinga permutogenetic body and containing a compound of an alkali-forming metal and at least one substance selected from the group consisting of dehydration catalysts, dehydrogenation catalysts, oxidation catalysts, dehydration catalysts.

5. A method of catalytically reducing car- ,bonyl compounds which comprisescausing them to react with reducing gases in the presence of a contact mass containing a permutogenct-ic body, at least a portion of the catalytically effective components being chemically combined in or with the permutogenetic, body.

6. A method of catalytically reducing carbonyl compounds which comprises causing them to react with reducing gases in the presence of a contact mass containing a permuto genetic body, at least a portion of the catalytically eli'ective components being chemically combined inor with the permutogenetic body in non-exchangcable form.

7. A method of cata'lytically reducing carbonyl compounds which comprises causing them to react with reducing gases inthe presence of a contact mass containing a diluted permutogenetic body.

8. A method according to claim 7 in which at least a portion of the catalytically effective components are present in the form of'diluents in the permutogenetic body.

9. A method of reducing products containing oxides of carbon which comprises causing them to react with reducing gases in the vapor phasein the presence of a contact mass containing a permutogenetic body.

lQ/A method of catalytieally reducing cont pounds capable of reduction containing oxides of carbon admixed with other organic compounds which comprises vaporizing the mixture and causing it to react with reducinggases in the presence of a contact mass containing a permutogenetie body.-

of contact masses favoring the productionof the intermediate product in suchstage and at least one contact mass used 1n at least one stage containing a permutogenetlc body.

13. A method of catalytically reducing materials containing oxygenated compounds which comprises causing them to react with reducing gases in the presence .of contact mastes containing permutogenetic bodies and at least one of the contact masses containing oxidation catalysts as stabilizer promoters.

14. A method of reducing products containing oxides of carbon to alcoholic products which comprises causing them to react with reducing gases in the vapor phase in the presence of a contact mass containing a permuto-.

genetic body and containing oxidation catalysts as stabilizer promoters in amounts less than those of the reduction catalysts.

' 15. A method of producing oxygenated compounds fromproducts containing oxides of carbon which comprises causing the latter to react with reducing gases in the presence of a contact mass containing a permutogenetic body and containing as its main catalytically active component groups including at least one of the elements copper, zinc, sil; ver, cadmium, lead.

16. A method according to claim 1 in which I at least a. portion of the reacted gases are-re circulated with removal of at least part of the reaction products and'with adjustment I of composition, pressure, and temperature to, initial reactlon condltlons.

Signed at Pittsburgh,Pennsylvania, thisb 16th day of February ,1928.'

ALPHONS O JAEGrER.- 

